Systems and methods for capping

ABSTRACT

Method and systems for capping are described. In one embodiment, an order processing device, a cap device, a plurality of feeders and a capping implement are provided. The order processing device processes orders with containers. The cap device is adapted to cap the container and is communicatively connected to the order processing device. The cap device is adapted to receive dispensation preferences from the order processing device. The cap device includes a plurality of feeders and a capping implement. Each feeder has a unique type of crown portion of a cap for capping. The capping implement is adapted to grasp the crown portion from the feeder. The cap device is adapted to select a feeder from which to grasp the crown portion based on the dispensation preferences. Additional methods and systems are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/412,584 filed on Mar. 5, 2012; said applicationclaims priority under 35 U.S.C. § 119(e) to U.S. Provisional PatentApplication No. 61/449,523 filed on Mar. 4, 2011. The entire disclosuresof U.S. application Ser. No. 13/412,584 and U.S. Provisional PatentApplication No. 61/449,523 are hereby incorporated herein by reference.

FIELD

The present application relates generally to the technical field ofautomated filling centers. In a specific example, the presentapplication may relate to a high volume fulfillment center, e.g., a highvolume pharmacy and to systems and devices used in filling prescriptionsand prescription orders at a high volume pharmacy.

BACKGROUND

A high-volume pharmacy, such as a mail order pharmacy, may process andfill a large number of prescriptions and prescription orders. Automatedsystems may be used by a high volume pharmacy to process and fulfillprescriptions.

A container that has been filled with a prescription drug via automationor manually may be capped or otherwise closed. Different styles of capsmay be preferred.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an example system according to an exampleembodiment;

FIG. 2 is a block diagram of an example order processing device that maybe deployed within the system of FIG. 1, according to an exampleembodiment;

FIG. 3 is a block diagram of an example cap device that may be deployedwithin the system of FIG. 1, according to an example embodiment;

FIG. 4 is a side view of a cap subsystem that may be deployed within thecap device of FIG. 3, according to an example embodiment;

FIG. 5A is a partial cross sectional view of a receiving portion of acap, according to an example embodiment;

FIG. 5B is a partial cross sectional view of a crown portion of a cap,according to an example embodiment;

FIG. 5C is a partial cross sectional view of a crown portion of a cap,according to an example embodiment;

FIG. 5D is a bottom view of the crown portion of FIG. 5C, according toan example embodiment;

FIG. 6A is a perspective view of a capping implement that may bedeployed within the cap subsystem of FIG. 4, according to an exampleembodiment;

FIG. 6B is a top view of the capping implement of FIG. 6A, according toan example embodiment;

FIG. 6C is a partial cross sectional view of the capping implement takenalong line C-C in FIG. 6B, according to an example embodiment;

FIG. 6D is a partial cross sectional view of the capping implement takenalong line D-D in FIG. 6B, according to an example embodiment;

FIG. 7A is a perspective view of a second housing that may be deployedin the capping implement of FIGS. 6A-6D, according to an exampleembodiment;

FIG. 7B is a bottom view of the second housing of FIG. 7A, according toan example embodiment;

FIG. 8A is a partial cross sectional view of a jaw assembly that may bedeployed in the capping implement of FIGS. 6A-6D, according to anexample embodiment;

FIG. 8B is a side view of a jaw member that may be deployed in the jawassembly of FIG. 8A, according to an example embodiment;

FIG. 8C is a perspective view of the jaw member of FIG. 8B, according toan example embodiment;

FIG. 9A is a bottom perspective view of a third housing that may bedeployed in the capping implement of FIGS. 6A-6D, according to anexample embodiment;

FIG. 9B is a top view of the third housing of FIG. 9A, according to anexample embodiment;

FIG. 10 is a magnified view of a sensor assembly in FIG. 6C, accordingto an example embodiment;

FIG. 11 is a block diagram of an example control subsystem that may bedeployed in the cap device of FIG. 3, according to an exampleembodiment;

FIG. 12 is an example process flow illustrating a method of capping,according to an example embodiment; and

FIG. 13 is a block diagram of a machine in the example form of acomputer system within which a set of instructions for causing themachine to perform any one or more of the methodologies discussed hereinmay be executed or stored.

DETAILED DESCRIPTION

Example systems and methods for capping are described. In the followingdescription, for purposes of explanation, numerous specific details areset forth in order to provide a thorough understanding of exampleembodiments. It will be evident, however, to one of ordinary skill inthe art that these embodiments may be practiced without these specificdetails.

Generally, different styles of caps may be required and/or preferred.For example, there may be a preference for a child-resistant cap whereasothers prefer a cap that opens more easily. Example capping systems andmethods disclosed herein accommodate a specific preference for a type ofcap.

The cap device may select the type of cap based on the preference bydirecting a robot to pick a crown portion of the cap from a designatedfeeder. Using a capping implement, the crown portion is grasped and fromthe feeder and placed on a receiving portion of the cap.

FIG. 1 is a block diagram of an example system 100, according to anexample embodiment. While the system 100 is generally described as beingdeployed in a high volume pharmacy, the automated filling system 100 mayotherwise be deployed. The system 100 may include an order processingdevice 102 in communication with a network manager device 106 over anetwork 104.

The order processing device 102 may receive information aboutprescriptions being filled at a pharmacy in which the order processingdevice 102 is deployed. The order processing device 102 may track aprescription order as it is fulfilled. The order processing device 102may make routing decisions and/or order consolidation decisions for aprescription order. The order processing device 102 may operate on itsown or in combination with the network manager device 106.

Examples of the network 104 include Mobile Communications (GSM) network,a code division multiple access (CDMA) network, 3rd GenerationPartnership Project (3GPP), an Internet Protocol (IP) network, aWireless Application Protocol (WAP) network, a WiFi network, or an IEEE802.11 standards network, as well as various combinations thereof. Otherconventional and/or later developed wired and wireless networks may alsobe used.

The network manager device 106 is a device operated by an entity atleast partially responsible for creation and/or management of thepharmacy benefit. While the network manager operating the networkmanager device 106 is typically a pharmacy benefit manager (PBM), otherentities may operate the network manager device 106 either on behalf ofthemselves, the PBM, or another entity. The network manager device 106may include a processor, memory to store data and instructions, and acommunication device.

Some of the operations of the PBM that operates the network managerdevice 106 may include the following. A member (or a person on behalf ofthe member) attempts to obtain a prescription drug at a retail pharmacylocation where the member can obtain drugs in a physical store from apharmacist or pharmacist technician, or in some instances through mailorder drug delivery from a mail order pharmacy location. The member mayalso obtain a prescription drug directly or indirectly through the useof a machine, such as a kiosk, vending unit, mobile electronic device,or a different type of computing device.

The member may have a co-pay for the prescription drug that reflects anamount of money that the member is responsible to pay the pharmacy forthe prescription drug. The money paid by the member to the pharmacy maycome from the personal funds of the member, a health savings account(HSA) of the member or the member's family, a health reimbursementarrangement (HRA) of the member or the member's family, a flexiblespending accounts (FSA) of the member or the member's family, or thelike. An employer of the member may directly or indirectly fund orreimburse the member or an account of the member for the co-pay.

The amount of the co-pay paid by the member may vary by the benefit planof the client with the PBM. The member's co-pay may be based on a flatco-pay (e.g., $10), coinsurance (e.g., 10%), and/or a deductible (e.g.,for first $500 of annual prescription drug spend) for certainprescription drugs, certain types of prescription drugs, and/or allprescription drugs.

In certain instances, the member may not pay the co-pay or may only payfor a portion of a co-pay for a prescription drug. For example, if theusual and customary cost for a generic version of a prescription drug is$4, and the member's flat co-pay is $20 for the prescription drug, themember may only pay $4 to receive the prescription drug. In anotherexample involving a worker's compensation claim, no co-pay may be due bythe member for the prescription drug.

In conjunction with receiving the co-pay (if any) from the member anddispensing the prescription drug to the member, the pharmacy submits aclaim to the PBM for the prescription drug. The PBM may perform certainadjudication functions including verifying the eligibility of themember, reviewing the formulary to determine appropriate co-pay,coinsurance, and deductible for the prescription drug, and performing adrug utilization review (DUR) on the member. The PBM then adjudicatesthe claim associated with the prescription drug and provides a responseto the pharmacy following performance of the aforementioned functions.As part of the adjudication, the client (or the PBM on behalf of theclient) ultimately reimburses the pharmacy for filling the prescriptiondrug when the prescription drug was successfully adjudicated. Theaforementioned adjudication functions generally occur before the co-payis received and the prescription drug dispensed. However, the operationsmay occur simultaneously, substantially simultaneously, or in adifferent order. In addition, more or less adjudication functions may beperformed as part of the adjudication process. Adjudication may beperformed through the use of a machine, such as a computer system.

The amount of reimbursement paid to the pharmacy by the client and/ormember may be based at least in part on the type of pharmacy network inwhich the pharmacy is included. Other factors may be used to determinethe reimbursement amount in addition to the type of pharmacy network.The above methodologies may be implemented by executing instructions inthe network manager device 106.

The system 100 may include a loading device 108, a sorting device 110,an automated dispensing device 112, a manual fulfillment device 114, areview device 116, a cap device 118, an accumulation device 120 and/or apacking device 122.

The loading device 108 may load prescription containers by a roboticarm, pick and place mechanism, or the like. In one embodiment, theloading device 108 has robotic arms or pickers to grasp a container andmove it to and from a pallet. The pallet may be located on a conveyorassembly.

The sorting device 110 may receive containers and may identify thecontainers that belong to a particular prescription drug order. Thesorting device 110 may group the containers according to theprescription drug order in which they belong.

The automated dispensing device 112 includes one or more devices thatdispense prescription drugs or pharmaceuticals into containers inaccordance with one or more prescription orders. Various automateddispensing systems are available commercially such as e.g., the systemsold under the trademark OPTIFILL by AmerisourceBergen Corporation.

The manual fulfillment device 114 provides for manually fulfillingprescriptions. In general, a manual fulfillment may include operationsat least partially performed by a pharmacist or pharmacy technician. Forexample, a person may retrieve a supply of the prescribed drug, may makean observation, may count out a prescribed quantity of drugs and placethem into a container, or the like. Some portions of the manualfulfillment process may be automated by use of a machine. For example,counting of capsules, tablets or pills may be at least partiallyautomated (e.g., through use of a pill counter). In some embodiments,the automated fulfillment is integrated with the manual fulfillmentoperations. Certain automated fulfillment may be performed before manualfulfillment and vice versa. The automated fulfillment for a prescriptionmay be paused to allow for the manual fulfillment to be completed. Oncethe devices receive an input that manual fulfillment is complete, thenthe automated fulfillment is released and fulfillment proceedsautomatically.

The review device 116 may process containers to be reviewed by apharmacist. Fulfilled prescriptions may be reviewed and/or verified by apharmacist, as may be required by state or local law. In otherembodiments, prescriptions are reviewed and/or verified for qualityassurance. A pharmacist or other licensed person who may dispensecertain drugs in compliance with local and/or other laws may operate thereview device 116 and visually inspect a container that has been filledwith a prescription drug. The pharmacist may review, verify, and/orevaluate drug quantity, drug strength, and/or drug interaction concerns,or otherwise perform pharmacist services.

The cap device 118 may be used to cap a container. In some embodiments,the cap device 118 may provide a type of cap in accordance with apatient preference (e.g., a preference regarding child resistance), aclient preference, prescriber preference, etc. The cap device 118 mayprovide a crown portion, such as a ring or top, to cap the container.The ring or top operates cooperatively to provide child resistance. Inother embodiments, no ring or top over a container may provide aneasily-opened cap (e.g., for patients with fine motor disabilities). Thecap is intended to close the opening into the container such that thecontents, e.g., prescription drugs, are contained for a specified shelflife and limit entry of dirt, oxygen, moisture, etc. into the container.The cap can further operate to reduce drying or out-gassing of thecontents in the container. The cap also may operate to keep the contentssecure from undesired premature opening (e.g., during delivery usingpackaging delivery services or mail services). In some embodiments, thecap may be able to re-close and re-open the container.

The accumulation device 120 accumulates various prescription drugs in aprescription order. The accumulation device 120 may accumulateprescription containers from various area of the high volume fulfillmentcenter. For example, the accumulation device 120 may accumulateprescription containers from the automated dispensing device 112, themanual fulfillment device 114, and the review device 116.

The packing device 122 packages a prescription order in preparation forshipping the order. The packaging device 122 may box or bag thefulfilled prescription order for delivery. The packaging device 122 mayfurther place inserts into the box or bag. The packaging device 122 maylabel the box or bag with the address. The packaging device 122 may sortthe box or bag for mailing in an efficient manner (e.g., sort bydelivery address).

While the system 100 in FIG. 1 is shown to include single devices 102,106-122 multiple devices may be used. The devices 102, 106-122 may bethe same type of device or may be different device types. When multipledevices are present, the multiple devices may be of the same device typeor may be a different device type. Moreover, system 100 shows a singlenetwork 104; however, multiple networks can be used. The multiplenetworks may communicate in series with each other to link the devices102, 106-122 or in parallel to link the devices 102, 106-122. Multipledevices may share processing and/or memory resources. The devices102-122 may be located in the same area or in different locations. Forexample, the devices 102, 106-122 may be located in a building or set ofadjoining buildings. The devices 102, 106-122 may be interconnected(e.g. by conveyors), networked or otherwise in contact with one another.

In some embodiments, at least some of the functionality of the orderprocessing device 102 may be included in the network manager device 106.In other embodiments, at least some of the functionality of the orderprocessing device 102 may be included in the cap device 118 and viceversa.

The order processing device 102 may be in a client-server relationshipwith the network manager device 106, a peer-to-peer relationship withthe network manager device 106, or in a different type of relationshipwith the network manager device 106.

The order processing device 102 and/or the network manager device 106may be in communication directly (e.g., through local storage) and/orthrough the network 104 (e.g., in a cloud configuration or software as aservice) with a database 124 (e.g., as may be retained in memory orotherwise). The database 124 may store order data 126, member data 128and/or client data 130.

The order data 126 may include data used for completion of theprescription, such as prescription materials. Prescription materials area type of order materials that include an electronic copy of informationregarding the prescription drug for inclusion with the fulfilledprescription. The prescription materials may include electronicinformation regarding drug interaction warnings, recommended usage,possible side effects, expiration date, date of prescribing, etc.

The member data 128 includes information regarding the membersassociated with the benefit manager. Examples of the member data 128include name, address, telephone number, e-mail address, prescriptiondrug history, and the like. The member data 128 may include a clientidentifier that identifies the client associated with the member and/ora member identifier that identifies the member to the client. The memberdata 128 may include a member identifier that identifies the clientassociated with the patient and/or a patient identifier that identifiesthe patient to the client. The member data 128 may also include, by wayof example, dispensation preferences such as type of label, type of cap,message preferences, language preferences, or the like. The member data128 may be accessed by the devices 102, 106-122 to obtain the necessaryinformation for fulfilling the prescription and shipping theprescription drugs.

The client data 130 includes information regarding the clients of thebenefit manager. Examples of the client data 130 include company name,company address, contact name, contact telephone number, contact e-mailaddress, and the like.

FIG. 2 illustrates the order processing device 102, according to anexample embodiment. The order processing device 102 may be used by oneor more operators to generate prescription orders, make routingdecisions, and/or make prescription order consolidation decisions. Forexample, the prescription order may be comprised of order components.The order processing device 102 may receive instructions to fulfill anorder without operator intervention. An order component may include aprescription drug fulfilled in a container by the system 100. The orderprocessing device 102 may direct an order component to the manualfulfillment device 114 or the review device 116 and direct othercomponents to the automated dispensing device 112. The order processingdevice 102 may direct all order components to the accumulation device120 for aggregation before shipping. The order processing device 102 maydirect the order components directly to the packing device 122 if theprescription order does not require accumulation from various areas ofthe pharmacy for completion. The order processing device 102 may bedeployed in the system 100, or may otherwise be used.

The order processing device 102 may include an order verificationsubsystem 202, an order control subsystem 204 and/or an order trackingsubsystem 206.

The order verification subsystem 202 may communicate with the networkmanager device 106 to verify the eligibility of the member, review theformulary to determine appropriate co-pay, coinsurance, and deductiblefor the prescription drug, and/or perform a drug utilization review(DUR).

The order control subsystem 204 controls various movements of thecontainers and/or pallets along with various filling functions duringprogression through the system 100. For example, the order controlsubsystem 204 may identify the prescribed drug as needing to befulfilled manually and may direct the container or order component tothe manual fulfillment device 114 to achieve the manual fulfillment. Thedevices 108-122 may be interconnected by a system of conveyors or othercontainer movement systems. Thus, the order control subsystem 204 maycontrol various conveyors to deliver the pallet from the loading device108 to the manual fulfillment device 114, for example.

The order tracking subsystem 206 tracks a prescription order as itprogresses (or stops) toward fulfillment. The order tracking subsystem206 may track, record and/or update order history, order status or thelike. The order tracking subsystem 206 may store data locally (e.g., ina memory) or at the order data 124.

Referring now to FIG. 3, a cap device 118 is illustrated according to anexample embodiment. The cap device 118 may be deployed in the system 100of FIG. 1. The cap device 118 may include a control subsystem 302 and acapping subsystem 304. The control subsystem 302 enables the cap device118 to control the capping subsystem 304. The capping subsystem 304enables the cap device 118 with capping operations (e.g., securing a capto a container).

Referring now to FIG. 4, the capping subsystem 304 is illustratedaccording to an example embodiment. The capping subsystem 304 mayinclude multiple crown feeders 402, a conveyor 404, a robot assembly 406and a capping implement 408. The crown feeder 402 is disposed adjacentthe robot assembly 406 and may be in the form of a chute, for example.The conveyor 404 delivers containers 410, disposed on a pallet 412, tothe robot assembly 406. The conveyor 404 may start and stop as desiredto allow for capping of the containers 410 with a cap 414. The robotassembly 406 includes a frame portion 416 and a robot 418. The frameportion 416 supports the robot 418 for operation. The frame portion hasan entrance 420 and an exit 422 that allow the conveyor 404therethrough. The conveyor 404 may deliver the pallet 412 through anentrance 420 of the robot assembly 406 and convey the pallet 412 throughthe robot assembly 406 to an exit 422. In the embodiment shown, therobot 418 is an Adept Quattro parallel robot such as that from AdeptTechnologies, Inc., Pleasanton, Calif. However, the robot 418 may beother types such as a SCARA robot from Adept Technologies, Inc.,Pleasanton, Calif. or Epson Robots, Carson, Calif. The capping implement408 may be disposed at an end portion of an arm of the robot 418. Thecapping implement 408 may be used to place at least a portion of the cap414 onto the container 410.

Referring to FIGS. 5A-5D, the cap 414 is illustrated according to anexample embodiment. The cap 414 may include a receiving portion 502 anda crown portion 504. The receiving portion 502 may be a separate capmember that threads onto a top of the container 410, for example. Thereceiving portion 502 may be adapted to mate with the crown portion 504.

Referring to FIG. 5A, the receiving portion 502 may include an annulargroove 506 in an exterior, e.g., outer diameter, of the receivingportion 502. In some embodiments, the receiving portion 502 includes theannular groove 506 integral with the container 410 such that the annulargroove 506 and the container 410 form a one-piece, unitary member withan opening of the container 410 being closed by the crown portion 504.

Referring to FIG. 5B, the crown portion 504 may include an annularprotrusion 508 along an inner diameter of the crown portion 504 and/or asecuring lip 510. The securing lip 510 may flex as the crown portion 504slides over the receiving portion 502. Once secure, the crown portion504 may no longer be removed because of engagement of the securing lip510 with the receiving portion 502. Other embodiments may includevarious male and female mating elements instead of or in addition to theannular groove 506 and the annular protrusion 508. In still otherembodiments, the outer diameter of the receiving portion 502 will besized and configured for a friction fit within the inner diameter of thecrown portion 504 in addition to or instead of the annular groove 506and the annular protrusion 508.

FIGS. 5C and 5D illustrate an embodiment of the crown portion 504 inwhich the crown portion 504 is ring-shaped, a partial cross-sectionalperspective view and a bottom view, respectively.

Referring to FIGS. 6A-6D, the capping implement 408 is illustratedaccording to an example embodiment. The capping implement 408 mayinclude a first housing 602, a second housing 604, a third housing 606,and a sensor assembly 608. The first housing 602 may house the secondand third housings 604, 606. The second housing may be connected to thesensor assembly 608. The third housing 606 may engage the crown portion504.

The first housing 602 may be cylindrically shaped and include anexterior surface 610 having an outer diameter, an interior surface 612having an inner diameter, a top portion 614, and a bottom portion 616.The exterior surface 610 may include a slot 618 running vertically andextending from the outer diameter to the inner diameter. The top portion614 may have a robot adapter 620 attached on an exterior to connect withan arm of the robot 418. The top portion 614 may include a spring bore622 at an interior with a diameter and depth to accommodate a topportion of a first spring 624 or biasing member. The bottom portion 616may include an inward annular flange 626.

The interior surface 612 may form a first cavity 628 within the firsthousing 602. The second housing 604 may be slidably disposed within thefirst housing 602 at the first cavity 628. The second housing 604 may becylindrically shaped with an outer diameter substantially the same asthe inner diameter of the interior surface 612 of the first housing 602.

Referring to FIGS. 7A-7B, the second housing 604 is illustratedaccording to an example embodiment. The second housing 604 may includean exterior surface 702 having an outer diameter, an interior surface704 having an inner diameter, a top portion 706, and a bottom portion708. The exterior surface 702 has multiple jaw slots 710 runningvertically from the top portion 706 to the bottom portion 708 andextending from the exterior surface 702 to the interior surface 704.Within the jaw slot 710, multiple dowel grooves 712 are formed. Betweenthe jaw slots 710, multiple fastener bores 714 are formed. A pin bore716 is formed through the exterior surface 702 between the slot 710 andthe fastener bore 714. The top portion 706 may include aspring-receiving protrusion 718 extending upwardly at a length forsecuring a bottom portion of the first spring 624. The spring protrusion718 may be cylindrical with a diameter sized to fit within the firstspring 624.

The interior surface 704 may form a second cavity 720 within the secondhousing 604. The third housing 606 may be slidably disposed within thefirst housing 602 at the first cavity 628. The third housing 606 may becylindrically shaped with an outer diameter substantially the same asthe inner diameter of the interior surface 612. The third housing may beattached to the second housing 604 so as to close a bottom portion ofthe second cavity 720.

Referring to FIGS. 8A-8C, the second housing 604 may include a jawassembly 800. The jaw assembly 800 may include multiple jaw members 802,multiple dowel pins 804, a push member 806 and a second spring 808 (orother second biasing member). The jaw member 802 may be sized to fitwithin the jaw slot 710. The jaw member 802 may include a first engagingarm 810 and a second engaging arm 812. The first engaging arm 810 isdisposed substantially perpendicular to the second engaging arm 812. Thefirst engaging arm 810 may include an engagement lip 814 that extendsdownwardly at an end portion opposite the junction of the first andsecond engaging arms 810, 812. The engagement lip 814 is adapted toengage the push member 806. The second engaging arm 812 may include adowel aperture 816, a platform groove 818, an engaging face 820, and anincline lip 822. The dowel aperture 816 is disposed in the secondengaging arm 812 with an inner diameter that slidably fits over an outerdiameter of the dowel pin 804. The platform groove 818 may be located ona side facing the first engaging arm 812. The platform groove 818 isadapted to accommodate at least a portion of the third housing 606. Theincline lip 822 is disposed at an end portion of the second engaging arm812 that is opposite the junction of the first and second engaging arms810, 812. The incline lip 822 is adapted to accommodate at least aportion of the third housing 606 and/or the crown portion 504. The crownportion 504 may be engaged with two or more jaw members 802, forexample. The engaging face 820 is adapted to engage the crown portion504.

The push member 806 may be a cylindrical, disc-like member disposedwithin the second cavity 720. The push member 806 may include adownwardly extending spring-receiving protrusion 824 for securing thesecond spring 808. The spring protrusion 824 may be sized with an outerdiameter for fitting inside the second spring 808. The second spring 808may be a REDUX wave spring from Lee Spring Company, Brooklyn, N.Y., forexample. The second spring 808 is disposed in the second cavity 720 toengage the push member 806 at one end and the third housing 606 at theother end.

Referring to FIGS. 9A and 9B, the third housing 606 is illustratedaccording to an example embodiment. The third housing 606 may include anexterior surface 902 having an outer diameter, an interior surface 904having an inner diameter, a top portion 906, and a bottom portion 908.The exterior surface 902 is slidably disposed at the interior surface612 of the first housing 602. The third housing 606 may be cylindricallyshaped with the top portion 906 having an outer diameter substantiallythe same as the inner diameter of the interior surface 612 and thebottom portion 908 having an outer diameter substantially the same as aninner diameter of the inward annular flange 626. The exterior surface902 may include multiple jaw grooves 910 adapted to accommodate the jawmembers 802.

The bottom portion 908 is adapted to accommodate the diameter of thecrown portion 504. The top portion 906 is attached to the bottom portion708 of the second housing 604 by fasteners running through the fastenerbores 714 and threaded into fastener threads 911. The top portion 906may include a spring bore 912 to accommodate the second spring 808. Thespring bore 912 may have a diameter to accommodate the diameter of thesecond spring 808. The top portion 906 may include an outwardlyextending annular flange 914. Within the jaw grooves 910, the annularflange 914 includes multiple dowel grooves 916. The top portion 906, asmated with the bottom portion 708, traps the dowel pin 804, extendingthrough the second engaging arm 812, within the dowel groove 712 and thedowel groove 916, thereby providing a pivoting location for the jawmember 802.

The bottom portion 908 may include an incline lip 918, a crownaccommodation section 920 and a bottom interior surface 922. The inclinelip 918 may provide clearance for the crown portion 504 as it enters orexits the bottom portion 908. The crown accommodation section 920 is anarcuate notch on an exterior of the bottom portion 908. The arcuatenotch has a diameter substantially equal to the diameter of the crownportion 504. Thus, the crown accommodation section 920 provides an areafor the crown portion 504 to rest against the third housing 606. Thebottom interior surface 922 is substantially the same diameter as theexterior of the crown portion 504. Thus, the bottom interior surface 922and the jaw members 802 may grasp the crown portion 504.

Referring to FIG. 10, the sensor assembly 608 is illustrated accordingto an example embodiment. The sensor assembly 608 may include a sensor1002, a pin or extension 1004 (or other elongate member) and bracket1006. The sensor 1002 may be a photosensor, for example, that iscommunicatively connected to the control subsystem 302. The pin 1004 issecurely fastened to the pin bore 716 of the second housing 604. The pin1004 extends through the slot 618 and past the sensor 1002. Thus, thepin 1004 travels vertically within the slot 618 with vertical movementof the second housing 604. The bracket 1006 is attached to the exteriorsurface 610 of the first housing 602 to secure the sensor 1002 proximalthe exterior surface 610 and the slot 618.

FIG. 11 illustrates an example control subsystem 302 that may bedeployed in the order processing device 102, the cap device 118, orotherwise deployed in another system. One or more modules arecommunicatively coupled and included in the control subsystem 302 toenable control of the capping. The modules of the control subsystem 302that may be included are a preference module 1102, a robot module 1104,and/or a sensor module 1106. Other modules may also be included.

In some embodiments, the modules of the control subsystem 302 may bedistributed so that some of the modules are deployed in the orderprocessing device 102 and some modules are deployed in the cap device118. In one embodiment, the modules are deployed in memory and executedby a processor coupled to the memory. The functionality contained withinthe modules 1102-1106 may be combined into a lesser number of modules,further divided among a greater number of modules, or redistributedamong existing modules. Other configurations including the functionalityof the modules 1102-1106 may be used.

The preference module 1102 accesses member or client dispensationpreferences from the order processing device 102 or the database 124,for example. Based on the dispensation preferences that dictate apreference of the cap 414 on the container 410, the preference module1102 may determine which feeder holds the desired crown portion 504 toform the preferred cap 414. The preference module 1102 may send theinformation to the robot module 1104.

The robot module 1104 may command the robot 418 to maneuver the cappingimplement 408 to the desired feeder. Based on the preferences determinedby the preference module 1102, the robot module 1104 may instructselection of a corresponding crown portion 504 by the robot 418 with therobot implement 408. Once the crown portion 504 is obtained, the robotmodule 1104 may command the robot 418 to maneuver the capping implement408 to the receiving portion 502 on the container 410. The robot module1104 may command the robot 418 to substantially align a longitudinalaxis of the capping implement 408 with a longitudinal axis of thecontainer 410 and/or the receiving portion 502. The robot module 1105may operate the robot 418 to skip capping of some containers 410 that donot require a crown portion 504 based on the dispensation preference.

The sensor module 1106 may monitor the sensor 1002. The sensor module1106 may coordinate with the robot module 1104 so as to determinewhether the capping implement 408 is engaged with the crown portion 504,when the capping implement 408 should disengage with the crown portion504, when the crown portion 504 is improperly lodged within the thirdhousing 606 or when the crown portion 504 is expected but not present atthe capping implement 408. The sensor module 1106 may determine thelocation of the pin 1004 or may track movement of the pin 1004 with thesensor 1002. In some embodiments, the sensor module 1106 may track thenumber of occurrences in which the sensor 1002 was unblocked or blockedby the pin 1004 as it moves within the slot 618.

FIG. 12 illustrates a method 1200 for capping, according to an exampleembodiment. The method 1200 may be performed by the cap device 118,partially by the order processing device 102 and partially by the capdevice 118, or may be otherwise performed.

At block 1202, the container 410 with a receiving portion 502 ispositioned for capping. The container 410 may be located on the pallet412 within the robot assembly 406 for engagement by the cappingimplement 408. The pallet 412 with the container 410 may be on theconveyor 404, may enter the robot assembly 406 through the entrance 420and may exit through the exit 422.

At block 1204, dispensation preferences for the container 410 areaccessed. Dispensation preferences may include a preference of the typeof the cap 414. The caps 414 may be of various colors besides white.Furthermore, a member or a client may have a preference on the color ofthe cap 414. Caps 414 of different sizes, shapes and/or functions mayalso be preferred by the member or the client. Ring crown portions 504(FIG. 5C) may be provided on containers 414 and/or crown portions 504that prevent child-proof tampering may be provided. Any combination ofcolor, size, shape, and function may be provided as a dispensationpreference.

At block 1206, a crown portion 504 of the cap 414 is selected based onthe dispensation preferences. The feeders 402 (FIG. 4) may each hold adifferent type of crown portion 504 for the robot 418 to select from.Based on determined dispensation preferences, a corresponding crownportion 504 is selected by the robot 418 with the robot implement 408.The robot 418 may align the robot implement 408 over the crown portion504 in the crown feeder 402.

The robot implement 408 may grasp the crown portion 504 as the robot 418applies downward pressure onto the first housing 602 of the robotimplement 408. As the crown portion 504 enters the third housing 606,the incline lip 822 and/or the incline portion 918 slide over the crownportion 504. The engaging face 820 of the jaw member 802 grasps thecrown portion 504 to hold the crown portion 504 at the third housing606. The jaw members 802 are biased to pivot so as to grasp the crownportion 504. The second spring 808 and the pressure member 806 applyspring force onto the first engaging arm 810. As the crown portion 504passes by the incline lip 822 and contacts the engaging face 820, thejaw members 802 pivot outwardly. The second engaging arm 812 is pushedoutwardly and pivots about the dowel pin 804 such that the firstengaging arm 810 applies downward force against the push member 806,compressing the second spring 808. As the second spring 808 iscompressed, increasing inward force is applied to the second engagingarm 812 and engaging face 820, thereby securing the crown portion 504inside the bottom portion 908. When downward pressure is applied by therobot implement 408 onto the crown portion 504, the second and thirdhousings 604, 606 move upward, compressing the first spring 624. Upwardmovement of the second housing 604 moves the pin 1004. When downwardforce onto the crown portion 504 is removed, the first spring 624 willdecompress, and pin 1004 will return to its original position.

At block 1208, the crown portion 504 of the cap 414 is moved to thecontainer 410. The robot 418 may move the robot implement 408, holdingthe crown portion 504, from the crown feeder 402 to the container 414.The robot 418 may align the robot implement 408 over the container 414.

At block 1210, the crown portion 504 of the cap 414 is mated with thereceiving portion 502. The robot 418 may apply a downward force onto therobot implement 408 that holds the crown portion 504. The downward forcemay be approximately 12 lbs, for example. The downward force causes theannular protrusion 508 and/or the securing lip 510 to slide over thereceiving portion 502 until mated. Mating may occur by the annularprotrusion 508 fitting into the annular groove 506 and/or the securinglip 510 snapping underneath the receiving portion. The weight of thecontainer 410 or mechanically securing the container 410 causes thecrown portion 504 to slip out of the jaw members 802 as the robot 418upwardly pulls the capping implement 408 away from the receiving portion502.

When downward pressure is applied by the robot implement 408 onto thecrown portion 504, the second and third housings 604, 606 move upward.Upward movement of the second housing 604 moves the pin 1004. Movementof the second and third housings 604, 606 can be tracked or verifiedwith the sensor 1002 by sensing movement of the pin 1004 in the slot618.

Without a crown portion 504 grasped by the jaw members 802, the pin 1004rests under the sensor 1002 at a bottom of the slot 618. That is, thepin 1004 does not block the sensor 1002. The pin 1004 is approximatelylocated at the bottom of the slot 618 when a crown portion 504 isgrasped by the jaw members 802. When the robot 418 applies downwardforce on the first housing 602 to mate the crown portion 504 with thereceiving portion 502, the pin 1004 may be forced upwardly so as totemporarily block the sensor 1002. The location of the pin 1004 may bedetermined or movement of the pin 1004 may be tracked with the sensor1002. In some embodiments, the number of occurrences in which the sensor1002 was unblocked or blocked by the pin 1004 as it moves within theslot 618 may be tracked.

FIG. 13 shows a block diagram of a machine in the example form of acomputer system 1300 within which a set of instructions may be executedcausing the machine to perform any one or more of the methods,processes, operations, or methodologies discussed herein. The orderprocessing device 102, the network manager device 106, and the capdevice 118 may include the functionality of the one or more computersystems 1300.

In an example embodiment, the machine operates as a standalone device ormay be connected (e.g., networked) to other machines. In a networkeddeployment, the machine may operate in the capacity of a server or aclient machine in server-client network environment, or as a peermachine in a peer-to-peer (or distributed) network environment. Themachine may be a server computer, a client computer, a personal computer(PC), a tablet PC, a gaming device, a set-top box (STB), a PersonalDigital Assistant (PDA), a cellular telephone, a web appliance, anetwork router, switch or bridge, or any machine capable of executing aset of instructions (sequential or otherwise) that specify actions to betaken by that machine. Further, while only a single machine isillustrated, the term “machine” shall also be taken to include anycollection of machines that individually or jointly execute a set (ormultiple sets) of instructions to perform any one or more of themethodologies discussed herein.

The example computer system 1300 includes a processor 1302 (e.g., acentral processing unit (CPU) a graphics processing unit (GPU) or both),a main memory 1304 and a static memory 1306, which communicate with eachother via a bus 1308. The computer system 1300 further includes a videodisplay unit 1310 (e.g., a liquid crystal display (LCD) or a cathode raytube (CRT)). The computer system 1300 also includes an alphanumericinput device 1312 (e.g., a keyboard), a cursor control device 1314(e.g., a mouse), a drive unit 1316, a signal generation device 1318(e.g., a speaker) and a network interface device 1320.

The drive unit 1316 includes a computer-readable medium 1322 on which isstored one or more sets of instructions (e.g., software 1324) embodyingany one or more of the methodologies or functions described herein. Thesoftware 1324 may also reside, completely or at least partially, withinthe main memory 1304 and/or within the processor 1302 during executionthereof by the computer system 1300, the main memory 1304 and theprocessor 1302 also constituting computer-readable media.

The software 1324 may further be transmitted or received over a network1326 via the network interface device 1320.

While the computer-readable medium 1322 is shown in an exampleembodiment to be a single medium, the term “computer-readable medium”should be taken to include a single medium or multiple media (e.g., acentralized or distributed database, and/or associated caches andservers) that store the one or more sets of instructions. The term“computer-readable medium” shall also be taken to include any mediumthat is capable of storing or encoding a set of instructions forexecution by the machine and that cause the machine to perform any oneor more of the methodologies of the present invention. The term“computer-readable medium” shall accordingly be taken to include, butnot be limited to, solid-state memories, and optical media, and magneticmedia. In some embodiments, the computer-readable medium is anon-transitory computer-readable medium.

The term “based on” or using, as used herein, reflects an open-endedterm that can reflect others elements beyond those explicitly recited.

Certain systems, apparatus, applications or processes are describedherein as including a number of modules. A module may be a unit ofdistinct functionality that may be presented in software, hardware, orcombinations thereof. When the functionality of a module is performed inany part through software, the module includes a computer-readablemedium. The modules may be regarded as being communicatively coupled.

The inventive subject matter may be represented in a variety ofdifferent embodiments of which there are many possible permutations.

In an example embodiment, a system is provided with an order processingdevice, a cap device, a plurality of feeders, and a capping implement.The order processing device is for processing orders with containers.The cap device is adapted to cap the container and is communicativelyconnected to the order processing device. The cap device is adapted toreceive dispensation preferences from the order processing device. Thecap device includes a plurality of feeders and a capping implement. Eachfeeder has a unique type of crown portion of a cap for capping. Thecapping implement is adapted to grasp the crown portion from the feeder.The cap device is adapted to select a feeder from which to grasp thecrown portion based on the dispensation preferences.

In an example embodiment, a container with a receiving portion forcapping is positioned. Dispensation preferences for the container areaccessed. A crown portion of a cap is selected based on the dispensationpreferences. The crown portion of the cap is moved to the container. Thecrown portion of the cap is mated with the receiving portion.

In an example embodiment, a capping implement is provided with a firsthousing, a second housing and a third housing, a first spring, a secondspring, a sensor assembly and a plurality of jaw members. The second andthird housings are disposed in the first housing. The first spring isdisposed between the first and second housing. The second spring isdisposed between the second and third housings. The sensor assembly isdisposed on the first and second housings. The sensor assembly isadapted for monitoring movement of the second housing and the thirdhousing. The jaw members are adapted to grasp a crown portion of a cap.The jaw members are pivotally disposed in a cavity of the first housing.

The present disclosure makes reference to the term “robot” and words ofsimilar import. A robot can be a machine capable of carrying out acomplex series of actions automatically. These complex series of actionsmay include picking up and placing a container, a cap or otherstructure. The robot may be dedicated to a single series of movements ormay be able to execute multiple series of movements. A robot may includea processor that received instructions and then executes instructions tocontrol its movement. In another example, a robot may resemble a humanbeing and replicate certain human movements and functions, e.g., a robotmay move location, have an articulated arm, have grasping structuresthat replicate like fingers and do not damage containers, caps or thelike.

Thus, methods and systems for capping have been described. Althoughembodiments of the present invention have been described with referenceto specific example embodiments, it will be evident that variousmodifications and changes may be made to these embodiments withoutdeparting from the broader spirit and scope of the embodiments of theinvention. Accordingly, the specification and drawings are to beregarded in an illustrative rather than a restrictive sense.

The methods described herein do not have to be executed in the orderdescribed, or in any particular order. Moreover, various activitiesdescribed with respect to the methods identified herein can be executedin serial or parallel fashion. Although “End” blocks are shown in theflowcharts, the methods may be performed continuously.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b), requiring an abstract that will allow the reader to quicklyascertain the nature of the technical disclosure. It is submitted withthe understanding that it will not be used to interpret or limit thescope or meaning of the claims. In addition, in the foregoing DetailedDescription, it can be seen that various features are grouped togetherin a single embodiment for the purpose of streamlining the disclosure.This method of disclosure is not to be interpreted as reflecting anintention that the claimed embodiments require more features than areexpressly recited in each claim. Rather, as the following claimsreflect, inventive subject matter may lie in less than all features of asingle disclosed embodiment. Thus, the following claims are herebyincorporated into the Detailed Description, with each claim standing onits own as a separate embodiment.

The invention claimed is:
 1. A system comprising: an order processingdevice to process an order including a plurality of containers locatedon a pallet; and a cap device adapted to cap a container of theplurality of containers and communicatively connected to the orderprocessing device, the cap device being adapted to receive dispensationpreferences from the order processing device, and the cap deviceincluding: a plurality of feeders, each feeder including a plurality ofcrown portions for capping, the plurality of the crown portions in eachfeeder having a crown portion type of a plurality of the crown portiontypes, wherein the cap device is adapted to select a feeder from amongthe plurality of feeders to grasp the crown portion based on thedispensation preferences, and wherein the dispensation preferencesinclude at least one of no crown portion required and crown portionrequired; and a capping implement adapted to grasp a crown portion ofthe plurality of the crown portions from the feeder of the plurality offeeders, wherein the capping implement includes a first housing, asecond housing, and a third housing, and wherein both the second housingand third housing are adapted to engage the crown portion when a crownportion is required.
 2. The system of claim 1, wherein each container ofthe plurality of the containers includes a receiving portion, thereceiving portion including an annular groove to secure the crownportion to the container.
 3. The system of claim 2, wherein thecontainer is closed by the crown portion.
 4. The system of claim 3,wherein the capping implement is further adapted to place the crownportion on the receiving portion.
 5. The system of claim 3, wherein oneof the dispensation preferences is for a child-resistant cap, and thecrown portion type in at least one of the plurality of feeders isconfigured to provide child resistance.
 6. The system of claim 3,wherein the crown portion includes an annular protrusion along an innerdiameter of the crown portion.
 7. The system of claim 3, wherein thecapping implement is further adapted to place the crown portion on thereceiving portion, wherein the crown portion includes a securing lipformed from an annular protrusion along an inner diameter of the crownportion, and wherein the securing lip flexes during at least some of aplacement process of placing the crown portion on the receiving portionby the capping implement.
 8. The system of claim 1, further comprising:a conveyor to convey a pallet with the plurality of containers throughthe cap device.
 9. The system of claim 8, further comprising: a loadingdevice to load the plurality of containers onto the pallet on theconveyor.
 10. The system of claim 1, wherein the second and thirdhousings are disposed in the first housing.
 11. The system of claim 10,wherein the capping implement includes a first spring disposed betweenthe first housing and the second housing and a second spring disposedbetween the second and third housings.
 12. The system of claim 10,wherein the capping implement includes a plurality of jaw memberspivotally disposed in a cavity of the first housing, and the jaw membersare adapted to grasp the crown portion of the plurality of the crownportions.
 13. The system of claim 1, wherein the capping implementcomprises a first spring disposed between the first housing and thesecond housing; a second spring disposed between the second and thirdhousings, wherein the second and third housings are disposed in thefirst housing; a sensor assembly disposed on the first and secondhousings, the sensor assembly being adapted for monitoring movement ofthe second housing and the third housing; and a plurality of jaw membersadapted to grasp the plurality of the crown portions, the plurality ofjaw members being pivotally disposed in a cavity of the first housing.14. The system of claim 13, wherein the sensor assembly includes a pinconnected to the second housing and extending through a slot in thefirst housing.
 15. The system of claim 13, wherein at least one jawmember of the plurality of jaw members includes a first engaging arm anda second engaging arm perpendicular to the first engaging arm.
 16. Asystem comprising: an order processing device to process an orderincluding a plurality of containers; and a cap device adapted to cap acontainer of the plurality of containers and connected to the orderprocessing device, the cap device being adapted to receive dispensationpreferences from the order processing device, and the cap deviceincluding: a plurality of crown feeders, each crown feeder including aplurality of crown portions, the plurality of crown portions in eachcrown feeder having a crown portion configuration of a plurality ofcrown portion configurations, each crown portion configured to interfacewith a receiving portion to form a cap for capping; and a cappingimplement adapted to grasp the crown portion from one of the pluralityof crown feeders; wherein the capping implement includes a firsthousing, a second housing, and a third housing, the second and thirdhousings being disposed in the first housing and both the second housingand third housing engage the crown portion, wherein the cappingimplement includes a first spring disposed between the first housing andthe second housing and a second spring disposed between the second andthird housings, and wherein the first spring is axially spaced from thesecond spring; wherein the cap device includes a control unit and thecapping implement includes a sensor assembly disposed at the first andsecond housings, the sensor assembly being adapted to monitor movementof the second and third housings, and wherein the dispensationpreferences include at least one of no crown portion required and crownportion required.
 17. The system of claim 16, wherein the sensorassembly includes a pin connected to the second housing and extendingthrough a slot in the first housing, and a sensor adapted to signal whenthe pin blocks the sensor.
 18. The system of claim 16, wherein thesensor assembly includes an extension associated with the second housingand interoperable with the first housing.
 19. The system of claim 18,wherein the sensor assembly includes a sensor adapted to send a changestate signal when the extension indicates a state change of one of thefirst housing and the second housing.